Sheet metal housing with precision mounting references

ABSTRACT

A sheet metal housing for an optical disk storage and handling apparatus which includes reference deformations provided in the sidewall panels of the sheet metal housing for locating mutually registerable components of the optical disk storage and handling system. A method of constructing such a sheet metal housing is also described.

CROSS REFERENCE TO RELATED APPLICATION

This is a division of application Ser. No. 07/344,191, filed Apr. 17,1989 now U.S. Pat. No. 4,944,082.

BACKGROUND OF THE INVENTION

The present invention relates generally to housings for computerperipherals and, more particularly, to a sheet metal housing for anoptical disk handling apparatus having a moving assembly adapted to bepositioned in registry with portions of a separately mounted staticassembly.

U.S. patent application Ser. No. 314,012 filed 2/22/89 for CARTRIDGEHANDLING SYSTEM of Wanger et al., which is hereby specificallyincorporated by reference for all that is disclosed therein, describesan optical disk storage and handling system. In that system, opticaldisks are transferred between a storage rack and a reading device bymeans of an automated handling assembly. In such an optical disk storageand handling system, the storage rack and reading device must to bepositioned at precisely referenced locations with respect to thestationary components of the handling assembly to ensure proper registryduring disk transfer operations.

In most computer peripheral devices in which a moving assembly is to bereferenced to another, separately mounted assembly, it is conventionalto provide a large, rigid reference base member upon which the differentassemblies are mounted. Such a base member provides a common, stableframe of reference for the various assemblies which are to be referencedwith one another. Reference base members are typically formed bymachining of large cast metal blocks.

Subsequent to mounting the various separate assemblies on the referencebase member, a housing constructed from less rigid material such as, forexample, sheet metal, plastic or the like, is mounted on the base memberto enclose the different assemblies. Due to the considerable cost offabricating such reference base members, and also due to theconsiderable weight of such base members, it would be desirable to findan alternative method of providing accurate apparatus mountingreferences.

OBJECTS OF THE INVENTION

It is an object of the present invention to provide a sheet metalhousing with precisely positioned mounting references for accuratelylocating components of an optical disk storage and handling system.

It is another object of the present invention to provide a method ofconstructing a sheet metal housing having precisely positioned mountingreferences.

It is another object of the present invention to provide a sheet metalhousing which obviates the need for heavy base reference members.

It is another object of the present invention to provide a sheet metalhousing with precisely positioned mounting references provided inlateral sidewall portions of the sheet metal housing.

It is another object of the present invention to provide a sheet metalhousing which is extremely rugged and reliable, which is relativelylightweight, and which is relatively inexpensive to produce as comparedto conventional housing structures for computer peripheral deviceshaving separately mounted registerable components.

SUMMARY OF THE INVENTION

The present invention is directed to a sheet metal housing and a methodof construction thereof which enables accurate location of separatelymounted, mutually registerable components of an apparatus, using onlythe sheet metal housing itself as a reference.

Thus, the invention may comprise a method of providing a sheet metalhousing with precisely positioned mounting references for accuratelylocating components of an apparatus which includes the following steps:

(1) Providing first and second sheet metal wall panels.

(2) Forming a pair of housing assembly reference deformations atprecise, predetermined positions on each of the wall panels.

(3) Forming apparatus locating deformations on each of the first andsecond wall panels at precise predetermined locations relative to thepair of housing assembly reference deformations on each wall panel.

(4) Mounting each of the wall panels on a predetermined portion of anassembly jig using the housing assembly reference deformations toprecisely locate each wall panel on the jig.

(5) Fixedly attaching other sheet metal wall panels between the firstand second sheet metal wall panel so as to provide a rigid housingstructure with the first and second sheet metal wall panels held in apredetermined fixed relationship.

(6) Removing the assembly jig from engagement with the first and secondsheet metal wall panels.

The invention may also comprise a sheet metal housing for an opticaldisk storage and handling apparatus which includes a top sheet metalwall panel, a bottom sheet metal wall panel, left and right sheet metalsidewall panels, and an intermediately positioned vertical sheet metalwall panel extending transversely of the sheet metal sidewall panels.Reference deformations are provided in the sidewall panels for locatingseparate, mutually registerable, mechanical components of the opticaldisk storage and handling system. The lateral sidewalls are preciselylaterally, longitudinally and vertically positioned relative to oneanother. The mutually registerable mechanical components of the opticaldisk storage and handling system are referenced, for mounting purposes,exclusively to the reference deformations in the lateral sidewallpanels.

BRIEF DESCRIPTION OF THE DRAWINGS

An illustrative and presently preferred embodiment of the invention isshown in the accompanying drawings in which:

FIG. 1 is a perspective view of a sheet metal housing.

FIG. 2 is a perspective view of a sidewall panel of a sheet metalhousing.

FIG. 3 is a detail perspective view of portions of a sidewall panel andbottom wall panel of a sheet metal housing.

FIG. 4 is a perspective view of a sidewall panel and bottom wall panelof a sheet metal housing.

FIG. 5 is a perspective view of a sidewall panel, bottom wall panel, andtransverse wall panel of a sheet metal housing.

FIG. 6 is a perspective view of a sidewall panel, bottom wall panel,transverse wall panel, and two separate top wall panels of a sheet metalhousing.

FIG. 7 is a perspective view of a housing assembly jig.

FIG. 8 is a side elevation view of a housing assembly jig.

FIG. 9 is an elevation view of a brace member used for spacing thesidewall panels of a sheet metal housing during assembly thereof.

DETAILED DESCRIPTION OF THE INVENTION The Invention In General

FIG. 1 illustrates a sheet metal housing 10 for an optical disk storageand handling apparatus 12, such as described in U.S. patent applicationSer. No. 314,012 of Wanger et al. and incorporated by reference above.In general, the sheet metal housing 10 comprises first and second topsheet metal wall panels 14, 16, a bottom sheet metal wall panel 18, aleft lateral sheet metal wall panel 20, a right lateral sheet metal wallpanel 22, and an intermediately positioned, transverse sheet metal wallpanel 24. Apparatus locating deformations 112-115, 120, 122, 130, 132,etc. which may comprise tabs, holes, or other deformations, are providedin the lateral sidewall panels 20, 22 for precisely locating separatelymounted mechanical components 52, 54, 56 of the optical disk storage andhandling system 12. Portions of static mechanical components 54, 56 areadapted to be placed in registration with (movable portions ofmechanical component 52) during handling system operation. The lateralsidewalls 20, 22 are precisely laterally (XX), longitudinally (YY), andvertically (ZZ) positioned relative to one another. The mutuallyregisterable machine components 52, 54, 56 of the optical disk storageand handling system 12 are referenced exclusively to the apparatuslocating deformations in the lateral sidewall panels 20, 22.

The method of constructing such a sheet metal housing with preciselypositioned mounting references comprises initially providing first andsecond sheet metal wall panels 20, 22 having a predetermined shape. Apair of housing assembly reference deformations such as holes 112, 114and 113, 115 are provided at precise predetermined positions on each ofthe wall panels 20, 22, FIGS. 1 and 2. Apparatus locating deformations,e.g. 130, 132, 134, 136, 172, etc., are provided on the wall panels 20,22 at precise, predetermined locations relative to the housing assemblyreference deformations 112, 114, etc. Each of the wall panels 20, 22 ismounted on a predetermined portion of an assembly jig 270, FIG. 7, usingthe associated pair of housing assembly reference deformations 112, 114and 113, 115 to precisely locate each wall panel on the jig. Other sheetmetal wall panels 14, 16, 18, 24 are then fixedly attached atpredetermined locations to the first and second sheet metal wall panels20, 22 so as to provide a rigid housing structure 10 in which the firstand second sheet metal wall panels are held in a predetermined, fixed,rigid relationship with one another. Next, the jig assembly 270 isremoved from engagement with the first and second sheet metal wallpanels 20, 22 and the various machine components 52, 54, 56, etc., aremounted at the various apparatus locating deformations 122, 124, etc. Inone embodiment of the invention, housing assembly reference deformations112, 114 and 113, 115 also function as apparatus locating deformations.

Having thus described the method and apparatus of the present inventionin general, various specific features thereof will now be described infurther detail.

Sheet Metal Housing

As illustrated in FIG. 2, the sheet metal housing comprises a leftsidewall panel 20 which, in the presently preferred embodiment, isconstructed from 1.9-millimeter-thick sheet steel. The left sidewallpanel 20 has a flat central body portion 102, which may have a length of672.3 millimeters and a height of 448.5 millimeters; a forwardlyextending front flange 104; a rearwardly extending rear flange 106; aninwardly extending top flange 108; and an inwardly extending bottomflange 110. A circular hole 112, which may be, e.g., 6.4 millimeters indiameter, is provided at a predetermined position on the central bodyportion 102 of panel 20. This position may be, e.g. 224.8 millimetersforward and 74.0 millimeters downward from the top rear edge of the flatcentral body portion 102. The circular hole 112 may comprise a firstreference point which is used in assembling the housing. A secondreference point which is to be used in assembling the housing maycomprise a vertically elongated hole or slot 114 which is provideddirectly vertically below circular hole 112 at a predetermined distancetherefrom, e.g. 300.5 millimeters, center to center. The slot 114 mayhave a longitudinal dimension of 6.4 millimeters and a verticaldimension of 12.0 millimeters, with the upper and lower ends thereofbeing semicircular in shape and having a radius of 3.2 millimeters. Thereference holes 112, 114, as well as being used in assembling thehousing, may also be used as mounting references for mounting amechanical component 52 of the optical disk handling apparatus 12 asdescribed in further detail below.

A plurality of other apparatus locating deformations are provided at apredetermined position on the flat central body portion 102 of thesidewall panel 20. Each of these other apparatus locating deformationsis precisely referenced to the housing assembly reference deformations112, 114. As illustrated in FIG. 2, the apparatus locating deformationsmay include first, second, third and fourth tabs 120, 122, 124, 126which are used to precisely locate an optical disk reading assembly 54,FIG. 1. Tabs 120 and 124 comprise horizontal, laterally extending slots121, 125 therein which are adapted to receive a locating tab (not shown)on the optical disk reading assembly 54 for precisely verticallylocating the optical disk reading assembly 54. Tab 122 comprises aforward edge surface 123 which is adapted to abuttingly engage apredetermined surface portion of the reading assembly 54 to preciselylongitudinally position the reading assembly. Tab 126 comprises aterminal end surface 127 which is adapted to abuttingly engage apredetermined surface portion of the reading assembly to preciselylaterally position the reading assembly. In the illustrated embodiment,the housing 10 is adapted to receive a reading assembly 54 comprisingtwo disk reading units mounted in side-by-side relationship. The leftsidewall tab surface 127 provides a precise reference for the left sideof the drive assembly 54. The right sidewall panel 22 has vertical andlongitudinal locating tabs identical to tabs 122 and 126 of the leftsidewall panel which are adapted to engage the right side of readingassembly 54. However, the right sidewall does not have deformationscorresponding to lateral locating tab 126. Rather, leaf springs (notshown) are inserted between the reading assembly 54 and the rightsidewall 22 to urge the reading assembly against left sidewall tabsurface 127.

In the illustrated embodiment, the housing assembly 10 is also adaptedto precisely locate a removable magazine assembly 56, FIG. 1, havingeight optical disk storage locations arranged in two vertical columnsconsisting of four storage units each. The left sidewall panel 20 maycomprise four substantially identical longitudinally extending rows oftabs which are adapted for precisely locating and mounting this opticaldisk magazine assembly. Each row of tabs includes a first, second, thirdand fourth laterally extending tab 130, 132, 134, 136. Tabs 132 and 136each comprise a horizontal, laterally extending slit 131, 135 thereinadapted to receive a thin horizontal plate portion (not shown) of themagazine assembly 56 for precisely vertically locating the magazineassembly. Tab 130 is adapted to receive the magazine assembly inabutting relationship therewith and comprises a screW hole 129 thereinfor securing the magazine assembly thereto for precisely longitudinallylocating the magazine assembly. Tab 34 comprises a vertically extendingterminal end surface 133 which is adapted to abuttingly engage a lateralside surface of the magazine assembly for precisely laterally locatingthe magazine assembly. The magazine assembly may be urged against thesurface 133 of tab 134 as by biasing springs (not shown) which arepositioned between the magazine assembly and the right sidewall panel22.

Wall panel locating deformations for initially positioning thetransverse wall panel 24 on the sidewall panel 20 prior to welding thewall panels together are provided in the form of a plurality of verticalslots 142, 144, etc., which are arranged in vertical alignment atpredetermined positions relative to the housing assembly referencedeformations 112, 114.

A stiffening member 146, FIG. 3, which extends substantially from thetop flange 108 to the bottom flange 110, FIG. 2 of the sidewall panel 20may be welded to the central body portion 102, at the positionillustrated in FIG. 3, prior to assembly of the various wall panels.

A plurality of welding cutouts 152, 154, etc., FIG. 2, are provided onthe top and bottom flanges 108, 110 to facilitate welding attachment oftop and bottom wall panels to the sidewall panel. A sidewall panelwindow cutout 162 having window flanges 164, 166 is provided tofacilitate assembly of the various components of the internally mountedoptical disk storage and handling apparatus 12 after assembly of thehousing 10.

The right lateral sidewall panel 22, FIG. 1, is essentially a mirrorimage of the left sidewall panel 20 having housing assembly deformations113, 115 corresponding exactly to deformations 112, 114 in the leftsidewall panel 20. Sidewall panel 22 has tabs 170, 172, etc.,corresponding to the tabs 120, 130, etc., in panel 20 used for locatingthe disk reading assembly 54 and storage magazine assembly 56 exceptthat, rather than having lateral positioning tabs corresponding to tabs126 and 134, etc., in the left sidewall panel 20, the right sidewallpanel has locating nubs 174, 176, etc., which serve to locate biasingsprings (not shown) which urge the storage magazine and the disk drivemounting assembly against the lateral positioning tabs 126, 134, etc.,on the left sidewall panel. The right sidewall panel is provided with astiffening member (not shown) corresponding to stiffening member 146 onthe left sidewall panel. A feature found on the right sidewall panelwhich is not present on the left sidewall panel is a reference cutout178 on the front flange 180 thereof which serves to precisely locate afront wall panel (not shown) which is attached to the housing 10 afterassembly thereof. The reference cutout 178 is precisely referenced tohousing assembly deformations 113, 115.

As illustrated in FIG. 4, the bottom wall panel 18 comprises a flatcentral body portion 190 having a rear flange 192 extending upwardlytherefrom. Transverse wall 24 locating slots 194, 196, etc., areprovided in lateral alignment on the central body portion 190. Otherwall panel deformations 198, 200, 202, etc., for facilitating attachmentof brace members and other non-reference-critical structure are providedon the flat central body portion 190. The relative assembledrelationship between the bottom wall panel 18 and the left lateralsidewall panel 20 is illustrated in FIGS. 3 and 4. The bottom wall panelcomprises a forward edge cutout 206 therein which is used for locating afront wall panel (not shown). The bottom wall panel may have astiffening member 205 welded thereto at a position thereon which willplace it in alignment with the welded members 146 (only one shown) onthe sidewall panels, FIG. 3.

Intermediate transverse wall panel 24, as illustrated in FIG. 5, has aflat central body portion 212 with a plurality of peripheral tabs 214,216 extending outwardly therefrom for facilitating initial location ofthe transverse wall panel with respect to other wall panels. A pluralityof air holes 218, 220, etc., are provided in a lower portion of thevertical wall panel for facilitating air flow through the housing. Slotsand holes 222, 224 facilitate mounting of various fans, motors, andsupport brackets on a rear surface of wall pan®1 24. Openings 221, 223enable mechanical linkage of drive motors, mounted rearwardly of wallpanel 24, to the displaceable optical disk handling assembly 52. In thepreferred embodiment of the invention, none of the various openingsprovided in the vertical wall panel are used for locating any componentsof the apparatus 12 in which precise referencing is necessary.

Forward, top wall panel 14 comprises a flat plate which is adapted to bewelded to the top flanges of the lateral sidewall panels 20, 22 asillustrated in FIGS. 1 and 6. Top wall panel 14 comprises a forward edgecutout 226 therein which is used for laterally locating a front wallpanel (not shown).

The rear top wall panel 16 comprise a flat central body portion 230having a downwardly extending rear flange 232. A plurality of laterallyaligned slots 234, 236, etc., are provided for facilitating initialplacement of the top wall panel 16 with respect to the transverse wallpanel 24. Other reference-non-critical attachment holes 238, 240 arealso provided in the top wall panel 16.

Jig Assembly

As illustrated in FIGS. 7-9, jig assembly 270 may comprise a pair ofvertical steel blocks 272, 274. Left upper and lower wall panelalignment plates 276, 278, and right upper and lower wall panelalignment plates 280, 282 are received in cavities provided in the blockmembers 272, 274 and are fixedly attached thereto as by attachment bolts284, 286. A pair of horizontal, laterally extending shafts 288, 290 arefixedly attached to vertical block 274 and are slidingly received inbushings 292, 294 which are fixedly mounted in bores provided invertical block 272. A cross plate 296 is fixedly attached as by bolts298, etc., to vertical block 274. A hole 310 in a left-hand portion ofcross plate 296 is adapted to be positioned in aligned relationship witha bore 311 in block 272 when the block members 272, 274 are positionedat a predetermined lateral spacing associated with the assembly ofhousing 10, as described in further detail hereinafter. A locking pin312 is adapted to be closely, slidingly received within hole 310 andbore 311 to hold block members 272, 274 at this fixed lateral spacing.Locking pin 312 may be provided with a harness 314 attached to the plate296 as by a bolt 316. The bushings 292, 294 enable the vertical blockmembers to be relatively laterally displaced from one another, from theassembly position illustrated in solid lines in FIG. 7 to a more closelypositioned relationship illustrated in phantom lines in FIG. 7, whichmay be, e.g. two inches closer.

Each block 272, 274 has a planar outer surface 273, 275 positioned inalignment with planar surfaces 322, 324 and 323, 325 of associatedalignment plates 276, 278 and 280, 282, respectively. Attachment screwholes 332, 334, 336, 338, etc., are provided on the planar surfaces ofeach of the alignment plates for enabling attachment of associatedhousing sidewall panels with screws 335, etc., as described in furtherdetail below. A dowel pin 340, 342 and 344, 346 is mounted on eachalignment plate, projecting a small distance, e.g. 0.25 inches,perpendicularly from the associated planar surface of each plate. In apreferred embodiment of the invention, dowel pins 340 and 342 arelocated coaxially with pins 344 and 346, respectively. The dowel pinsare adapted to be closely slidingly received within associated sidewallpanel deformations 112-5.

As illustrated in FIG. 9, a pair of identical cross brace shaft members350 (only one shown) may be provided which are used for accuratelyspacing front end portions of the housing sidewall panels 20, 22 duringhousing assembly. The cross brace members may each comprise narrowterminal end projections 354, 356 which are adapted to abuttingly engageassociated portions of the housing sidewall panels 20, 22. Each of thenarrow end projections has a threaded hole therein for enablingattachment of the end projections in abutting engagement to anassociated sidewall panel by associated attachment screws 358, 360. Thedistance between terminal ends of each cross brace shaft member 350 maybe identical to the spacing between the sidewall engaging planarsurfaces 273, 275 of the vertical block members when the block membersare positioned in the locked position illustrated in solid lines in FIG.7.

Method of Assembling Housing

In one preferred embodiment of the invention, the housing assembly isassembled upside-down and the top surfaces of the vertical blocks of thejig assembly are placed on a support stand (not shown).

To assemble the housing 10, the left sidewall panel 20 is initiallymounted with dowel pins 340 and 342 received through hole 112 and slot114, and with the interior surface of wall panel 20 positioned inabutting engagement with planar surface 273 of vertical post 272 andplanar surfaces 322 and 324 of alignment plates 276, 278. Next, sidewallpanel 20 is secured against the associated abutment surfaces by use ofmachine screws 335, etc., received through holes 337, 339, etc., FIG. 2,in the side panel and associated holes, e.g. 336, 338, in the supportplate.

Next, the transverse vertical wall panel 24 is loosely positioned inregistration with the sidewall panel 20 by means of the slots 142, 144,etc., provided in the sidewall panel 20 and the associated tabs providedon the transverse vertical wall panel 24. Next, the right sidewall panel22 is secured to the right-hand portion of the jig 270 in a manneridentical to that in which the left sidewall panel 20 was secured to theleft-hand portion of the jig. During mounting of the right sidewall 22on the jig assembly, the associated tab portions of the transverse wallpanel 24 are inserted into the associated vertical slots in the rightsidewall panel

Next, the brace members 350 (only one shown) are positioned atpredetermined upper and lower forward end portions of the sidewallpanels and held in fixed relationship therewith by associated set screwsreceived through screw holes, e.g. 341, FIG. 2, in the sidewall panels20, 22. The brace members thus serve as spacers for maintaining theforward ends of the sidewall panels 20, 22 in parallel relationship.

Next, the bottom wall 18 is laid loosely in position with the associatedslots therein positioned in registry with the tabs on the bottom of thetransverse wall panel 24.

Next, the top wall panels 14 and 16 are slipped into their appropriatepositions with registration indicia (not shown) provided on the toppanels 14, 16 positioned in registration with registration indicia (notshown) provided on the sidewall panels 20, 22.

Next, the wall panels 14, 16, 18, 20, 22 24 are welded together alongthe seams therebetween and at welding cutout areas, 152, 154, etc., toprovide the rigid box-shaped housing assembly 10 shown in solid lines inFIG. 1.

Next, the lock pin 312 is removed from the jig fixture 270 and thevertical posts 272, 274 are moved laterally inwardly from the associatedsidewall portions sufficiently far so as to remove the dowels 340, 342,344, 346 from the associated receiving holes in the sidewall panels.Thereafter, the jig fixture is moved longitudinally forwardly within thehousing assembly so as to remove it through the forward opening thereindefined by wall panels 14, 18, 20 and 22.

Thus, a rigid sheet metal housing 10 having precisely located mountingreferences, e.g. 112-115, 120, 130, etc., has been provided. Next, thevarious mutually registerable components 52, 54, 56 of the apparatus 12which is to be mounted in the housing structure are mounted at thevarious precisely positioned mounting references: vertical post portionsof handling assembly 52 are mounted at references 112, 114 and 113, 115;disk reading assembly 54 is mounted at references 20, 170, etc.; andstorage magazine assembly 56 is mounted at references 30, 172, etc.Thus, components 52, 54, 56 are positioned in precise, predeterminedrelationship and are referenced exclusively to portions of sidewallpanels 20, 22.

In one preferred embodiment of the invention, the housing transversewall panel 24, rear top wall panel 16, and rear portions of the sidewallpanels 20, 22 and the bottom wall panel 18 define portions of a Faradaycage which is used to enclose RF-emitting components of the optical diskhandling apparatus 12.

While an illustrative and presently preferred embodiment of theinvention has been described in detail herein, it is to be understoodthat the inventive concepts may be otherwise variously embodied andemployed and that the appended claims are intended to be construed toinclude such variations except insofar as limited by the prior art.

What is claimed is:
 1. A sheet metal housing for an optical disk storageand handling apparatus comprising:a top sheet metal wall panel, a bottomsheet metal wall panel, left and right sheet metal sidewall panels, andan intermediately positioned vertical sheet metal wall panel extendingtransversely of said left and right sheet metal sidewall panels and saidbottom sheet metal wall panel; reference deformations provided in saidsidewall panels for locating different mutually registerable mechanicalcomponents of the optical disk storage and handling apparatus; saidsidewalls being precisely laterally, longitudinally and verticallypositioned relative one another; said mutually registerable machinecomponents of said optical disk storage and handling apparatus beingreferenced for mounting int he housing exclusively to said referencedeformations in said sidewall panels.
 2. The invention of claim 1, saidreference deformations being adapted to precisely locate said mutuallyregisterable components in a lateral direction, a longitudinal directionand a vertical direction.